The plate used was something I used for another project earlier so I just used that even though it is only normal mild steel. It is 2mm thick and I don`t know the size of the shuriken as I drew it much larger and decreased its size with a printer.
I started of by drawing rough sketches of the entire shuriken until I found the angles that looked best. I then drew only one of the blades on a full A4 paper sheet and decreased it`s size until my cousin said It was good.
When I had the size and shape of the blade on a piece of paper I cut it out as precisely as possible and then drew a fine outline of the paper blade on the steel plate, I drew it six times as it`s a six blade design.
I chose to use a pneumatic angle grinder for the cutting as it allows for fine precision cutting and just traced the lines and left some room to work with a beltsander/file to get the size and angles just right.
This is the pieces before they got an edge.
I shaped the six blades until I was happy with them and then meassured out the area where the edge would be so that I could get them placed roughly in line so that it would look neat. The edges was created on a beltsander.
It was now ready for welding. I placed a steel ruler on a steel plate so that I would have a perfectly straight startingpoint. Since it`s a six bladed shuriken I started with three and placed them against the ruler so that I got two close to perfect halves that could later be welded tougether.
First I spot welder both the halves and then I tacked the two halves together. It was now ready to fully weld.
When the shuriken was assembled I started grinding the welds away with an angle grinder and smoothing it out with a pneumatic angle grinder before a rough polish.
I then took a pneumatic microgrinder and engraved my cousins first letter onto the shuriken to give it a personal touch and then I went over the outer edge of the entire shuriken with the microgrinder to ensure it was spotless and now it`s ready:
So what do you think?
